Flux focusing arrangement for permanent magnets, methods of fabricating such arrangements, and machines including such arrangements

ABSTRACT

Numerous arrangements for permanent magnets are disclosed that can focus the flux produced by the magnets. Depending on the particular application in which the disclosed designs and techniques are used, efficiency and reliability may be increased by minimizing flux leakage, increasing peak flux density, and shaping the flux fields to improve the effective coercivity of the flux focusing permanent magnet arrangement when loaded, and to achieve customized voltage and current waveforms. The disclosed magnet assemblies may be incorporated into a machine, such as a motor/generator, having windings and may be disposed for movement relative to the windings. The magnet assembly may be mounted on a support formed of one or more ferromagnetic materials, such as a back iron The disclosed flux focusing magnet assemblies may be formed using a variety of manufacturing methods.

PRIORITY

This application claims the benefit of U.S. Provisional Application Ser.No. 61/517,086, filed Apr. 13, 2011, the disclosure of which isincorporated herein by reference.

FIELD OF THE INVENTION

The disclosure relates to the field of permanent magnets, including theuse of permanent magnets and permanent magnet arrangements in machineryand other devices.

BACKGROUND OF INVENTION

Permanent magnet electromagnetic machines (referred to as permanentmagnet machines herein) utilize magnetic flux from permanent magnets toconvert mechanical energy to electrical energy or vice versa. Varioustypes of permanent magnet machines are known, including axial fluxmachines, radial flux machines, and transverse flux machines, in whichone component rotates about an axis or translates along an axis, eitherin a single direction or in two directions, e.g. reciprocating, withrespect to another component. Such machines typically include windingsto carry electric current through coils that interact with the flux fromthe magnets through relative movement between the magnets and thewindings. In a common industrial application arrangement, the permanentmagnets are mounted for movement, e.g. on a rotor (or otherwise movingpart) and the windings are mounted on a stationary part, such as astator. Other configurations, typical for low power, inexpensivemachines operated from a direct current source where the magnets arestationary and the machine's windings are part of the rotor (energizedby a device known as a “commutator” with “brushes”) are clearly alsoavailable, but will not be discussed in detail in the following text inthe interest of brevity

In an electric motor, for example, current is applied to the windings inthe stator, causing the magnets (and therefore the rotor) to moverelative to the windings, thus converting electrical energy intomechanical energy. In a generator, application of an external force tothe generator's rotor causes the magnets to move relative to thewindings, and the resulting generated voltage causes current to flowthrough the windings—thus converting mechanical energy into electricalenergy.

Surface mounted permanent magnet machines are a class of permanentmagnet machines in which the magnets are mounted on a ferromagneticstructure, or backing, commonly referred to as a back iron. Suchmachines are generally the lowest cost and lightest weight permanentmagnet machines, but they typically suffer from limitations inperformance that can be traced to the flux density limitations, wellknown in the art, of conventionally designed and manufactured permanentmagnets. As a general matter, flux density can be increased by usingmagnets formed of a material having a relatively higher magnetic energydensity, or of relatively greater thickness. High magnetic energydensity materials, such as the neodymium-iron-boron system, aretypically more expensive and have historically been subject tosignificant price volatility. Thicker magnets require more magneticmaterial, and cost generally scales with the amount of materials. Thus,increasing flux density for such machines with these approachesincreases cost and potentially increases cost volatility, and may yieldonly limited performance improvements. Further, there is an inherentlimit to the amount of flux in a given magnetic circuit, where furtheradditions to magnet thickness may yield little to no additional flux.

Given the drawbacks of known techniques of improving the electromagneticefficiency and other performance attributes of surface mounted machines,new techniques for effecting such performance improvements are clearlydesired by those practiced in the art of designing such machines.Further, because many applications of permanent magnets other thanpermanent magnet machines as described above would benefit from theability to enhance magnetic performance while limiting cost, such newtechniques will be even more desirable if they have broad applicabilitynot limited to permanent magnet machines.

The benefits of the disclosed designs and techniques will be apparent tothose practiced in the art of designing and building surface mountedpermanent magnet machines. In fact, the benefits of the discloseddesigns and techniques may enable surface mounted magnet machines tocompete with other permanent magnet machine topologies (such as embeddedmagnet machines) on performance while retaining the established cost andweight advantages of surface mounted permanent magnet machines.Moreover, the benefits and usefulness of the disclosed designs andtechniques are not limited to surface mounted permanent magnet machines,but extend to a wide variety of permanent magnet applications.

SUMMARY

Illustrative embodiments are shown in the drawings and described below.It is to be understood, however, that there is no intention to limit theclaimed inventions to the particular forms described in this Summary ofthe Invention or in the Detailed Description. One skilled in the art canrecognize that there are numerous modifications, equivalents, andalternative constructions that fall within the spirit and scope of theclaimed inventions. In particular, one skilled in the art can recognizethat the disclosed designs and techniques can be used in any machinewith arrays of magnets, including radial, axial, and transverse fluxmotors and generators that operate in a rotating or a linear manner.Indeed, skilled artisans will also recognize that the disclosed designsand techniques are useful in any application that utilizes magnetic fluxfrom permanent magnets.

Numerous arrangements for permanent magnets are disclosed that can focusthe flux produced by the magnets. Depending on the particularapplication in which the disclosed designs and techniques are used,efficiency and reliability may be increased by minimizing flux leakage,increasing peak flux density, and shaping the flux fields to improve theeffective coercivity of the flux focusing permanent magnet arrangementwhen loaded, and to achieve customized voltage and current waveforms.

By way of non-limiting example, a flux focusing magnet assembly mayinclude a first magnet or magnet portion having a nominal axis ofpolarization, and one or more other magnets or magnet portions disposedadjacent to or about the first magnet, each such other magnet or magnetportion having a nominal axis of polarization that converges with thenominal axis of polarization of the first magnet. The nominal axis oraxes of the other magnet(s) or portion(s) may be coplanar or may benon-coplanar with the nominal axis of polarization of the first magnetand/or each other. The nominal axes of the magnets or magnet portionsmay converge in the direction of their north poles, or may converge inthe direction of their south poles. The magnet assembly may include aferromagnetic lens to further concentrate flux. The magnet assembly maybe incorporated into a machine having windings and may be disposed formovement relative to the windings and oriented such that nominal axes ofpolarization converge towards the windings, or such that the nominalaxes of polarization converge away from the windings. The magnetassembly may be mounted on a support formed of one or more ferromagneticmaterials, such as a back iron.

The disclosed flux focusing magnet assemblies may be formed using avariety of manufacturing methods. By way of non-limiting example, two ormore separate magnets may each be formed separately in the presence of amagnetic field to align the magnetic domains in each magnet parallel toa nominal axis of polarization, the magnets may be positioned ordisposed adjacent each other with their nominal axes of polarizationconverging, and then the assembly can be permanently magnetized.Alternatively, each magnet may be permanently magnetized before themagnets are disposed adjacent each other. Alternatively, a unitarymagnet may be formed in the presence of a complex magnetic field toalign the magnetic domains in different portions of the magnet to alignthe magnetic domains parallel to different nominal axes of polarization,and then may be permanently magnetized in a complex magnetic field. Aferromagnetic lens may be coupled to the magnet(s) before or afterpermanent magnetization and/or before or after multiple magnets aredisposed adjacent each other.

These and other embodiments are described in further detail herein.

BRIEF DESCRIPTION OF THE DRAWINGS

In the following Detailed Description, reference is made to the drawingsidentified below.

FIG. 1 is a schematic illustration of a magnet assembly according to anembodiment.

FIG. 2A is a schematic perspective view of a magnet assembly accordingto an embodiment having two magnets, and FIG. 2B is a schematic crosssectional view of the assembly taken along line 2B-2B of FIG. 2A.

FIG. 2C is a schematic cross sectional view of a variation on theassembly of FIG. 2A.

FIG. 3 is a schematic cross-sectional view of a north pole flux focusingmagnet assembly according to an embodiment.

FIG. 4 is a schematic cross-sectional view of a south pole flux focusingmagnet assembly according to an embodiment.

FIGS. 5A-5F are schematic perspective views of various configurations ofa an embodiment of a flux magnet assembly with a central magnet and twosplitter magnets.

FIG. 6A is a schematic perspective view of a magnet assembly accordingto an embodiment having ten magnets, and FIG. 6B is a schematic crosssectional view of the assembly taken along line 6B-6B of FIG. 6A.

FIG. 7A is a schematic perspective view of a magnet assembly accordingto an embodiment having one magnet, and FIG. 7B is a schematic crosssectional view of the assembly taken along line 7B-7B of FIG. 7A.

FIG. 8 is a schematic cross sectional view of an embodiment in which thecentral magnet has a different rating than that of the splitter magnets.

FIGS. 9A and 9B are schematic cross-sectional views of a flux focusingmagnet assembly having two pusher magnets according to an embodiment.

FIGS. 10A-10D are schematic perspective views of various configurationsof a an embodiment of a flux magnet assembly with a central magnet, twosplitter magnets, and a pusher magnet.

FIG. 11 is a schematic cross-sectional view of a north pole fluxfocusing magnet assemblies having splitter magnets and a lens accordingto an embodiments.

FIG. 12 is a schematic cross-sectional view of a south pole fluxfocusing magnet assembly having splitter magnets and a lens according toan embodiment.

FIGS. 13A and 13B are schematic cross-sectional views of a flux focusingmagnet assembly having two pusher magnets and a lens according to anembodiment.

FIG. 14 is a schematic cross-sectional view of a flux focusing magnetassembly having a pusher magnet and a lens according to an embodiment.

FIGS. 15A-15E are schematic perspective views of various configurationsof an embodiment of a flux magnet assembly with a central magnet, twosplitter magnets, a lens, and optionally a pusher magnet.

FIG. 16 is a schematic illustration of a pole assembly having at leasttwo flux focusing magnet assemblies, according to an embodiment.

FIGS. 17A-17F are schematic perspective views of various embodiments ofpole assemblies having one or more flux focusing magnet assemblies.

FIG. 18 is a schematic illustration of a magnetic assembly having twopole assemblies, according to an embodiment.

FIG. 19 is a schematic perspective view of a magnetic assembly havingtwo pole assemblies, according to an embodiment.

FIGS. 20A, 20B, and 20C are schematic cross-sectional views of themagnetic assembly of FIG. 19, taken along lines 20A-20A, 20B-20B, and20C-20C, respectively.

FIG. 21 is a schematic perspective view of a magnetic assembly havingtwo pole assemblies, according to an embodiment.

FIGS. 22A, 22B, and 22C are schematic cross-sectional views of themagnetic assembly of FIG. 19, taken along lines 22A-22A, 22B-22B, and22C-22C, respectively.

FIG. 23 is a schematic cross section of a magnetic assemblyincorporating side inserts, according to an embodiment.

FIGS. 24A and 24B are schematic cross sections of magnetic assemblieswith alternative back iron structures, according to additionalembodiments.

FIG. 25 is a schematic illustration of flux flows in a magneticassembly, according to an embodiment.

FIG. 26A is a schematic illustration of a magnetic machine incorporatingtwo magnetic assemblies, according to an embodiment.

FIG. 26B is a schematic illustration of a magnetic machine incorporatingone magnetic assembly, according to an embodiment.

FIG. 27 is a perspective view of an axial motor/generator according toan embodiment.

FIG. 28 is a partial exploded view of the motor/generator of FIG. 27.

FIG. 29 is an enlarged perspective view of a segment of a rotor of themotor/generator of FIG. 27.

FIG. 30 is a detail perspective view of the portion of FIG. 28identified as “A” in FIG. 29.

FIG. 31 is a detail perspective view of a rotor segment of amotor/generator according to an embodiment.

FIG. 32 is a detail perspective view of a pole assembly of themotor/generator of FIG. 31.

FIG. 33 is a perspective view of a radial field motor/generatoraccording to an embodiment.

FIG. 34 is a perspective view of a segment of the rotor of themotor/generator of FIG. 33.

FIG. 35 is a schematic cross-sectional view of the motor/generator ofFIG. 33.

FIG. 36 is a schematic cross-sectional view of a radial fieldmotor/generator according to an embodiment.

FIG. 37 is a schematic cross-sectional view of a transverse fluxmotor/generator according to an embodiment.

FIG. 38 is a perspective view of a portion of the motor/generator ofFIG. 37.

FIG. 39 is a perspective view of the rotor of the motor/generator ofFIG. 37.

FIG. 40 is a flow chart showing a first method of manufacturing a fluxfocusing magnet assembly;

FIG. 41 is a flow chart showing a second method of manufacturing a fluxfocusing magnet assembly;

FIG. 42 is a flow chart showing a third method of manufacturing a fluxfocusing magnet assembly;

FIG. 43 is a flow chart showing a fourth method of manufacturing a fluxfocusing magnet assembly;

FIG. 44 is a flow chart showing a fifth method of manufacturing a fluxfocusing magnet assembly; and

FIG. 45 is a flow chart showing a sixth method of manufacturing a fluxfocusing magnet assembly.

DETAILED DESCRIPTION

The flux focusing magnet assemblies described below may be beneficiallyused in any application that utilizes magnetic flux, and areparticularly useful in those applications where it is desired tomaximize the flux that crosses a gap while minimizing leakage flux,improving the peak flux density across the gap, and/or shaping the fluxfield across said gap.

A flux focusing magnet assembly 20 is illustrated schematically inFIG. 1. Magnet assembly 20 includes a first magnet 21 and a secondmagnet 22 disposed adjacent to first magnet 21. The magnetic domains ineach magnet are aligned parallel to a respective nominal flux axis, eachrepresented in FIG. 1 by one or more arrows, which for the first magnet21 are labeled “Flux,” with the head of each arrow having the samepolarity (e.g. north or south). As shown in FIG. 1, the nominal fluxaxes of magnets 21 and 22 are not parallel, but are oriented towardseach other, to converge in a direction above the magnets. As the artisanwill recognize, the flux field produced by the combination of the twomagnets 21 and 22, i.e. by the converging nominal flux axes, is denserin the region above the magnets than would be the flux field produced bythe two magnets if their nominal flux axes were parallel. The nominalflux axes of magnets 21 and 22 may be coplanar or may lie in differentplanes. Magnet assembly 20 has an overall nominal flux direction,indicated by the arrow labeled Flux_(MA). The nominal flux direction ofthe magnet assembly is influenced by the flux axes of the constituentmagnets of the magnet assembly, or stated another way, the relativeorientation of the magnets' flux axes can be selected to product adesired nominal flux direction of the magnet assembly, for examplenormal to the face of the magnet assembly.

Optionally, magnet assembly 20 may include a third magnet 23, which maybe disposed adjacent to magnet 21 so that magnets 22 and 23 are onopposite sides of magnet 21. The nominal flux axis of magnet 23 mayconverge with those of magnets 21 and 22, which the artisan willrecognize will produce a flux field that is more dense in the regionabove magnet assembly 20 than would be the flux field produced bymagnets 21 and 22 alone, or by magnets 21, 22, and 23 if their nominalflux axes were parallel. The nominal flux axis of magnet 23 may becoplanar with the nominal flux axis of magnet 21 and/or that of magnet22, or may not be coplanar with either.

In a magnet assembly in which a second magnet is disposed on one sideof, or in which second and third magnets are disposed on opposite sidesof (which may be referred to as “laterally” of, or along a lateraldirection) a first magnet, with their nominal flux axes converging, thefirst magnet may be referred to as a central magnet, and the second, orsecond and third magnets, may be referred to as a splitter magnet orsplitter magnets, or for an assembly with just two magnets, both may bereferred to as splitter magnets, and neither magnet is referred to as acentral magnet. Magnet assembly 20 may include one or more additionalsplitter magnets (not shown) disposed on either or both sides of magnets21, 22, and 23.

An exemplary magnet assembly 120 with central magnet (or splittermagnet) 121 and splitter magnet 122 (or two splitter magnets 121, 122)is illustrated schematically in FIGS. 2A and 2B. FIG. 2A shows aschematic perspective view, and FIG. 2B shows a schematic cross section,of a north pole flux focusing magnet assembly with magnets 121 and 122.While each of magnets 21 and 22, and flux focusing magnet assembly 20 asa whole, is illustrated as having a substantially rectangular crosssection in FIG. 2A, this is merely for ease of illustration; skilledartisans will understand that the geometric cross section of a fluxfocusing magnet assembly 20 will vary depending on the size and shape ofits component magnets, and the characteristics desired in a particularapplication where such a magnet is utilized, as described in more detailbelow.

As shown in FIG. 2B, central magnet (or splitter magnet) 121, andsplitter magnet 122, each has an angle of polarization, or nominal fluxaxis, oriented to converge towards the other magnet's nominal flux axisabove the top face of magnet assembly 120. The top face of magnetassembly 120 in FIG. 2B has a magnetization of north while the bottomface has a magnetization of south. The orientation of the nominal fluxaxes, and the polarity of the poles, of magnets 121 and 122, results inmagnetic flux directed angularly toward the center of, and upwardrelative to, magnet assembly 120, from the north pole face of magnetassembly 120. The magnetic angle of polarization of magnets 121 and 122determines how much flux each contributes to the useful flux densityabove the north pole face of magnet assembly 120.

A variation on magnet assembly 120 is shown in FIG. 2C. In thisvariation, the nominal flux axes are not symmetric with each other, i.e.the flux angle of magnet 122 is at a smaller angle with respect to thenominal flux axis Flux_(MA) of magnet assembly 120 than is that ofmagnet 121.

Another exemplary magnet assembly 220 is shown in schematic crosssection if FIG. 3. Magnet assembly 220 is a north pole flux focusingmagnet assembly, with a central magnet 221 and two splitter magnets 222,223. In FIG. 3A, central magnet 221 has an angle of polarization, ornominal flux axis, oriented perpendicular to the top face of magnetassembly 220, whereas splitter magnets 221 and 222 have flux paths at anangle of polarization, or a nominal flux axis, of minus and plus 45°relative to that of the central magnet 221, i.e. the nominal flux axesconverge in a direction above the top face. The top face of magnetassembly 220 in FIG. 3 has a magnetization of north while the bottomface has a magnetization of south. The orientation of the nominal fluxaxes, and the polarity of the poles, of magnets 221, 222, and 223,results in magnetic flux directed angularly toward central magnet 221from splitter magnets 222 and 223, and upward (relative to magnetassembly 220) from the north pole face of magnet assembly 220. Themagnetic angle of polarization of splitter magnets 222 and 223determines how much flux splitter magnets 222 and 223 contribute to theuseful flux density above the north pole face of magnet assembly 220.

FIG. 4 schematically illustrates a magnet assembly 320 similar to thatillustrated in FIG. 3 except that the polarity is reversed, i.e. magnetassembly 320 is a south pole magnet assembly, in which central magnet321 has an angle of polarization opposite a nominal flux direction. Inthis arrangement, the flux of central magnet 321 is oriented to bedirected downward (relative to magnet assembly 320), and splittermagnets 322 and 323 are arranged on each side of the central magnet andoriented at a 45° angle away from the angle of polarization of centralmagnet 321, as shown. The top face of magnet assembly 320 has amagnetization of south while the bottom face of magnet assembly 320 hasa magnetization of north. The orientation of the poles in magnets 321,322, and 323, in combination with the orientation of the angle ofpolarization of splitter magnets 322 and 323, results in magnetic fluxfrom splitter magnets 322 and 323 directed angularly away from centralmagnet 321, and downward (relative to magnet assembly 320) from thenorth pole face of magnet assembly 320.

The amount of useful flux contributed by splitter magnets of fluxfocusing magnet assemblies such as those shown in FIGS. 1, 3, and 4, isgreater than the amount of useful flux that would be contributed bystraight-polarity magnets of the same dimensions, because thecross-sectional area normal to the angle of polarization of the splittermagnets is greater than the cross-sectional area normal to the angle ofpolarization of a straight polarity magnet of the same dimensions.

In any given application of a flux focusing magnet assembly, such asassembly 20 in FIG. 1, the angle of polarization of splitter magnet 22(and optionally splitter magnet 23) in magnet assembly 20 may beanything less than 90° greater than or less than the angle ofpolarization of central magnet 21, i.e. converging, so as to direct fluxangularly toward the flux emanating from central magnet 21 (for a northpole flux focusing magnet assembly) or away from the flux enteringcentral magnet 21 (for a south pole flux focusing magnet assembly).

The dimensions and angle of polarization of central magnet 21 andsplitter magnet 22 (and/or splitter magnet 23) can be adjusted to shapethe flux field generated by magnet assembly 20. For example, in anelectromagnetic machine having one rotor and one stator, wherein aplurality of magnet assemblies 20 are mounted on the rotor, thecircumferential width and angle of polarization of splitter magnets 22and/or 23 can be adjusted to shape the flux field across the gap betweenthe rotor and the stator (as described in more detail below) so as tominimize total harmonic distortion and produce a sinusoidal electricalwaveform. The same characteristics of splitter magnets 22 and 23 canalso be adjusted to maximize peak flux density in applications wherethat particular property is desirable. Persons skilled in the art willunderstand how to adjust the relative dimensions and angle of polarityof the individual segments of flux focusing magnet assembly 20 tooptimize the desired characteristics and achieve a useful configurationfor a given application. Such configurations may include, by way ofexample only, a splitter magnet 22 that is wider than central magnet 21(and optional splitter magnet 23) or a splitter magnet 22 having thesame width as splitter magnet 23, where both splitter magnet 22 and 23are narrower but taller than central magnet 21.

Additional examples of relative shapes and sizes of central magnets 21and splitter magnets 22, 23 in various configurations of flux focusingmagnet assembly 20 with three magnets are shown schematically in FIGS.5A-5F. Each of the illustrated configurations includes a main or centralmagnet 21 and splitter magnets 22, 23 disposed laterally on oppositesides of central magnet 21. Although not indicated in the figures, eachof splitter magnets 22, 23 has a nominal flux axis that convergestowards the other, and toward the nominal flux axis of central magnet21. As can be seen from FIGS. 5A-5F, the size and shape of each of themagnets can vary considerably. For example, in the magnet assemblyillustrated in FIG. 5A, each of the magnets is approximately the samesize, and of constant (though different) cross section in the lateraland longitudinal directions, whereas FIG. 5D illustrates that themagnets can be of constant cross section but that central magnet 21 maybe significantly larger than splitter magnets 22, 23. FIGS. 5B and 5Fillustrate that magnet assembly can vary in thickness (perpendicular tothe pole face, indicated by N or S) along the lateral direction. FIG. 5Bfurther illustrates that splitter magnets 22, 23 may have lateral facesor sides that are not perpendicular to the pole face of magnet assembly20. Optionally, the lateral faces of splitter magnets 22, 23 may beapproximately parallel to their nominal flux axes. FIGS. 5C and 5Eillustrate that the cross sections of the central and/or splitter\magnets may vary in the longitudinal direction. The illustratedconfigurations are merely illustrative, and are not meant to belimiting. The illustrated variations in relative sizes and geometries ofcentral and splitter magnets are equally applicable to magnet assemblieswith two, or four or more magnet, and are not limited to the illustratedthree-magnet assemblies.

As noted above, a flux focusing magnet assembly can have more than threemagnets. In such arrangements, the angle of polarization, or theorientation of the nominal flux axis, of each segment may be alteredmarginally in a step-wise fashion from one adjacent segment to another,and ranging between a magnetic angle of polarization of 0° relative tothe nominal flux direction at the central magnet up to anything lessthan 90° greater than or less than the nominal flux direction for themagnets on the edges of the magnet assembly. For example, as shown inFIGS. 6A and 6B, magnet assembly 420 includes magnet segments 421 a and422 a, which are positioned immediately adjacent to the center of magnetassembly 420, have angles of polarization slightly less than andslightly greater than the nominal angle of polarization, respectively.Each successive magnet segment 422 (i.e. 422 b, 422 c, 422 d, 422 e) hasan angle of polarization greater than the magnet segment immediatelypreceding it, while each successive magnet segment 421 (i.e. 421 b, 421c, 421 d, 421 e) has an angle of polarization less than the magnetsegment immediately preceding it. Magnet assembly 420 is shown in FIGS.6A and 6B with ten magnet segments for purposes of illustration only;magnet assemblies may have any number of individual magnet segments.

Alternatively, a flux focusing magnet assembly may be formed from asingle magnet segment. An exemplary embodiment is shown in schematicperspective view in FIG. 7A and in cross section in FIG. 7B. As shown inFIG. 7B, magnet assembly 520 has a single segment, in which the magneticdomains of the magnet material are not aligned parallel to one another.Magnet assembly 520 has a variable magnetic angle of polarization ornominal flux axis relative to a top surface of magnet assembly 520 fromthe center to the edges. The variation in the magnetic angle ofpolarization for the magnet assembly 520 can range from 0° to anythingless than 90° greater than or less than the nominal angle ofpolarization so that flux emanating from the side portions of magnetassembly 520 is directed angularly toward the flux emanating from thecenter portion of magnet assembly 520 at the nominal angle ofpolarization (for a north pole flux focusing magnet assembly) or awayfrom the flux emanating from the center portion of magnet assembly 520at the nominal angle of polarization (for a south pole flux focusingmagnet assembly).

Beneficial flux concentrations can also be achieved by utilizing magnetsof different performance specification for the central permanent magnetand the splitter magnets. For example, in the case ofneodymium-iron-boron (NdFeB) magnets, it is widely known to describemagnetic material performance by a rating for energy product and/ormagnetic remanence Br as well as an operating temperature rating and/orcoercivity rating. For example, a magnet with a rating of N48 provides ahigher flux density in a given magnetic circuit than a magnet with arating of N45, and a magnet with a rating of N45M has a highercoercivity than a magnet with a rating of N45. The cost of a magnettypically increases with its flux density rating and its coercivityrating. One advantage of the disclosed flux focusing magnet assemblydesigns is that the concentration of flux caused by the flux focusingarrangement enables the splitter magnets to have a lower flux densitythan the central magnet without significantly affecting the flux densityof the magnet assembly overall. Another advantage is that the coercivityof the central magnet can be lower than the coercivity of the splittermagnets without compromising the overall effective coercivity of magnetassembly, which will remain at or near the level of coercivity of thesplitter magnets. Thus, as shown in the exemplary embodiment in FIG. 8,flux focusing magnet assembly 620 can have a central magnet 621 with arating of N45 and splitter magnets 622, 623 can have a flux rating ofN45M. Due to the added flux path length of the splitter magnets, fluxfocusing arrangements such as magnet assembly 620 provide an improvedloading condition in operation that can be expressed as a higher “net”coercivity or resistance to demagnetization than in a magnet arrangementwhere the angle of polarization of splitter magnets 622 and 623 isparallel to the angle of polarization of central magnet 621. Thesefeatures allow for reductions in magnet cost without a correspondingreduction in overall performance, or an improved performance without anincrease in cost. More generally, each of the magnets in the fluxfocusing magnet assemblies described herein can be different, whether insome performance specification, material, dimension, etc. from any orall of the other magnets.

Yet another advantage of the disclosed flux focusing magnet assemblydesigns is that the individual magnet segments need not be made of thesame material. For example, the central magnet could be made of NdFeB,while the splitter magnets could be made of AlNiCo, SmCo, or anothermaterial. These materials are referenced solely for purposes ofillustration; any suitable permanent magnet material can be used for theany one or more of the central magnet and the splitter magnets.

Returning to FIG. 1, magnet assembly 20 may optionally include a fourthmagnet 24, which may be disposed adjacent an end of first magnet 21(i.e. in a direction that is transverse or orthogonal to the lateraldirection, which may be referred to as a longitudinal direction). Thenominal flux axis of fourth magnet 24 may converge with, and may becoplanar or non-coplanar with, the nominal flux axis of first magnet 21.In the illustrated embodiment, the nominal flux axis of fourth magnet 24converges with the nominal flux axis of first magnet 21 and the axes areapproximately coplanar in a plane approximately parallel to thelongitudinal direction. When included in a magnet assembly that includesa main magnet and one or more splitter magnets disposed laterally of themain magnet, a magnet disposed longitudinally of the main magnet may bereferred to as a “pusher” magnet. Magnet assembly 20 may furtheroptionally include a second pusher magnet 25 disposed on thelongitudinally opposite end of magnet assembly 20 from pusher magnet 24.As with the splitter magnets, one or more additional pusher magnets (notshown) may be disposed on either or both ends of pusher magnets 24 and25. For clarity, the splitter magnets of magnetic assembly 720 are notshown in these schematic views.

An exemplary magnet assembly 720 with central magnet 721 and pushermagnets 724, 725 is illustrated in schematic cross-section in FIGS. 9Aand 9B. While each of magnets 721, 724, and 725 is illustrated as havinga substantially rectangular cross section, this is merely for ease ofillustration; skilled artisans will understand that the geometric crosssection of a flux focusing magnet assembly will vary depending on thesize and shape of its component magnets, as described in more detailbelow.

As shown in FIG. 9A, central magnet 721 has an angle or polarization ornominal flux direction that is in the nominal flux direction of magnetassembly 720, and pusher magnet 724 has an angle of polarization, ornominal flux axis, oriented to converge towards that of central magnet21 above the top face of magnet assembly 720. Similarly, as shown inFIG. 9B, pusher magnet 725 has an angle of polarization, or nominal fluxaxis, oriented to converge towards that of central magnet 721 above thetop face of magnet assembly 720. The top face of magnet assembly 720 inFIGS. 9A and 9B has a magnetization of north while the bottom face has amagnetization of south. The orientation of the nominal flux axes, andthe polarity of the poles, of central magnet 121 and pusher magnets 724,725, results in magnetic flux directed angularly toward the center of,and upward relative to, magnet assembly 720, from the north pole face ofmagnet assembly 7120. The magnetic angle of polarization of magnets 721,724 and 725 determines how much flux each contributes to the useful fluxdensity above the north pole face of magnet assembly 720.

In the illustrated embodiment, pusher magnet 724 has an angle ofpolarization of plus 45° relative to the nominal flux direction ornominal flux axis of central magnet 721, and pusher magnet 725 has anangle of polarization of minus 45° relative to the nominal fluxdirection. The angle of polarization of pusher magnets 724 and 725,however, may be anything less than 90° greater than or less than thenominal angle of polarization of central magnet 721 so as to direct fluxangularly toward the flux emanating from central magnet 721 (for a northpole flux focusing magnet assembly) or away from the flux emanating fromcentral magnet 721 (for a south pole flux focusing magnet assembly).

Pusher magnets achieve a result similar to that of splitter magnets, butin a different direction: splitter magnets constrain leakage flux offthe sides of a flux focusing magnet assembly, whereas pusher magnets 44and 46 constrain leakage flux off the ends of the magnet assemblies.Also, while splitter magnets can be used to shape the flux distributionacross the width of a magnet assembly, pusher magnets can be used toshape the flux distribution along the length of the magnet assembly.

Additional examples of relative shapes and sizes of central magnets 21,splitter magnets 22, 23, and a pusher 24 magnet in variousconfigurations of flux focusing magnet assembly 20 are shownschematically in FIGS. 10A-10D. Each of the illustrated configurationsincludes a main or central magnet 21, splitter magnets 22, 23 disposedlaterally on opposite sides of central magnet 21, and a pusher magnet 24or 25 disposed longitudinally on one end of central magnet 21. Althoughnot indicated in the figures, each of splitter magnets 22, 23 has anominal flux axis that converges towards the other, and toward thenominal flux axis of central magnet 21 and magnet assembly 20.Similarly, each pusher magnet 24 or 25 has a nominal flux axis thatconverges towards the nominal flux axis of central magnet 21 and magnetassembly 20. As can be seen from FIGS. 10A-10D, the size and shape ofeach of the magnets can vary considerably. For example, in the magnetassembly illustrated in FIGS. 10A and 10B, each of the magnets isapproximately the same size, and of constant (though different) crosssection in the lateral and longitudinal directions, though in FIG. 10Athe pusher magnet 25 is at one end of magnet assembly 20, whereas inFIG. 10B the pusher magnet 24 is at the opposite end of magnet assembly20. In contrast, FIG. 10C illustrates that pusher magnet 25 can have thesame thickness as the other magnets but have a triangular or taperedshape in plan view. Similarly, FIG. 10D illustrates that magnet assembly20 can vary in thickness (perpendicular to the pole face, indicated byS) along the lateral direction. The illustrated configurations aremerely illustrative, and are not meant to be limiting.

For magnet assemblies as described above having two or more magnets, theinterfaces between the constituent magnets may be of any one or more ofa variety of geometries or types, including mitered, lapped, andvariable.

As discussed above, beneficial flux concentrations and distributions canalso be achieved by utilizing magnets of different performancespecification or of different materials in magnet assembly 20 having oneor more pusher magnets 24, 25. More particularly, splitter magnets 22and 23, and/or pusher magnets 24 and/or 25 can have a different ratingthan central magnet 21 for any one or more characteristics such asenergy product, magnetic remanence, operating temperature, andcoercivity. Each of central magnet 21, splitter magnets 22 and 23,and/or pusher magnets 24 and 25 may be made from the same magneticmaterial, or from two or more different magnetic materials. Further, therelative dimensions of central magnet 21, splitter magnets 22 and 23,and pusher magnets 24 and 25 may be varied to achieve a beneficial fluxconcentration and distribution for a given application. Each of theabove variations may be further be beneficial for reducing the costand/or improving the overall performance of magnet assembly 20.

As discussed above, each of magnets 21, 23, 23, 24, 25 (and any of theadditional magnets described above but not shown in FIG. 1) may be adistinct, separate magnet. Alternatively, any two or more, or all of,the magnets may be a region or portion of a single magnet, in whichregion the magnetic domains are aligned parallel to the respectivenominal flux axis of the region.

For the north pole flux focusing magnet assemblies described above(other than assembly 220), the corresponding south pole configuration isnot shown or described, but would not differ structurally from theconfiguration of the north pole as described above. The flux paths ofthe corresponding south pole magnet assemblies, however, are directlyopposite the flux paths of the north pole magnet assemblies depicted inthose figures.

As also shown in FIG. 1, magnet assembly 20 may optionally include alens 28, disposed adjacent to the magnet(s). Lens 28 may be formed of aferromagnetic material having a relatively high magnetic permeability,which enables lens 28 to contain flux from the interfacing magnets inmagnet assembly 20 at a higher flux density than the constituent magnets21, 22, 23, 24, and/or 25 themselves. The shape of lens 28 may be variedso that the combined flux at the pole face of magnet assembly 20 can beconcentrated to a desired flux density. Lens 28 can also be used tocontrol the density distribution over the entire pole face of magnetassembly 20, so as to ensure that a greater percentage of the total fluxis available for use. Depending on the application in which magnetassemblies 20 is being used, the shape of lens 28 can be optimized tominimize leakage flux, or to achieve a desirable combination of reducedleakage flux and flux density distribution.

The use of a ferromagnetic lens 28 with flux focusing magnet assemblieshelps achieve beneficial flux concentrations. Additionally, the fluxfield shape and harmonics created by flux focusing magnet assemblies 20can be manipulated by shaping the pole face of the lens 28, e.g. to beplanar, convex, concave, etc., as discussed in more detail below. Whenflux focusing magnet assemblies are used in electromagnetic machines,these characteristics affect the voltage and current waveforms of thosemachines.

An exemplary arrangement of lens and magnets is shown schematically inFIG. 11. In this embodiment, splitter magnets 822 and 823 can bearranged to cover the edges of lens 828 so as to provide additional fluxconcentration at the magnet assembly face and to prevent flux leakagefrom the lateral faces of lens 828. FIG. 11A illustrates a north polemagnet assembly. The embodiment illustrated in FIG. 12 is similar,except that splitter magnets 922, 923, center magnet 921, and lens 928form a south pole magnet assembly. Other variations in the geometry ofthe interface between splitter magnets and lens are possible; forexample, in some embodiments, the lens may extend outward over thesplitter magnets or the pusher magnet(s), while in other embodiments,the lens may be coterminous with the adjacent face of the centralmagnet. For example, FIG. 13A illustrates a magnet assembly 1020 inwhich lens 1028 is coterminous with the adjacent face of central magnet1021, and abuts pusher magnet 1025. Similarly, FIG. 13B illustratesmagnet assembly 1020 in which lens 1028 is coterminous with the adjacentface of central magnet 1021, and abuts pusher magnet 1024.

Although the lens is shown in the preceding embodiments as beingrectangular in cross-section, as mentioned above the lens can have othercross-sectional shapes. For example, as shown in FIG. 14, magnetassembly 1120 has a recess formed between splitter magnets 1122, 1123above central magnet 1121. Lens 1128 is disposed in the recess, and hasa convex upper surface, which further shapes the flux density above theface of the magnet, which in machine applications, for instance, may beleveraged to achieve greater torque density and/or reduced harmonicdistortion. Alternatively, as shown in FIG. 24A below, the lens may havea concave upper surface.

Any flux focusing magnet assembly configuration can be used inconjunction with a ferromagnetic lens. The length and width of the lenscan be the entire length and width of the magnet assembly with which itis used, or it can be centered predominantly over a central magnet, asshown in FIGS. 11 and 12. The size and shape of the lens can beoptimized for any particular flux path or gap distance desired.

Additional examples of relative shapes and sizes of central magnets 21,splitter magnets 22, 23, and a pusher 24 magnet in variousconfigurations of flux focusing magnet assembly 20 are shownschematically in FIGS. 15A-15E. Each of the illustrated configurationsincludes a main or central magnet 21, splitter magnets 22, 23 disposedlaterally on opposite sides of central magnet 21, and a lens 28. Someconfigurations include a pusher magnet 24 or 25 disposed longitudinallyon one end of central magnet 21. As can be seen from FIGS. 15A-15E, thesize and shape of each of the magnets and of the lens can varyconsiderably. For example, in the magnet assembly illustrated in FIG.10A, each of the splitter magnets 22, 23 is approximately the same size,and of constant cross section in the lateral and longitudinaldirections, and central magnet 21 and lens 28 are also of constant crosssection, but their collective thickness equals that of splitter magnets22, 23. FIG. 15B illustrates that lens 28 can have the same width ascentral magnet 21 at their interface, and can increase in width towardsthe top face of magnet assembly 20. Conversely, FIG. 15E illustratesthat central magnet 21 can narrow towards the interface with lens 128.FIG. 15D illustrates that lens 28 and central magnet 21 can havenon-planar interfaces, i.e. can have thickness that vary, e.g. along thelateral direction. FIG. 15C illustrates that the interface betweenpusher magnet 25 and the other components of magnet assembly 20 can benon-planar. The illustrated configurations are merely illustrative, andare not meant to be limiting.

Multiple magnet assemblies can be placed end to end to form a poleassembly. FIG. 16 schematically illustrates a pole assembly 30 composedof two flux focusing magnet assemblies 20, 20′. Pole assembly 30 mayinclude a third magnet assembly 20″, or may have four or more magnetassemblies. In this embodiment, each of magnet assemblies 20, 20′ is anorth pole magnet assembly, and collectively define a “north pole” poleassembly 30. Alternatively, south pole magnet assemblies could becombined to form a “south pole” pole assembly. Each of the constituentmagnet assemblies in a pole assembly may be of any of the configurationsdescribed above (e.g. formed from one, two, three or more magnets, withsplitter magnet(s), pusher magnet(s), and/or a lens).

Various exemplary embodiments of pole assemblies are illustrated inFIGS. 17A-17F. FIG. 17A shows a south pole assembly 1130 formed of fiveidentical flux focusing magnet assemblies 1120. FIG. 17B shows a northpole assembly 1230 formed of three central magnet assemblies 1220 eachhaving a center magnet 1221 and splitter magnets 1222, 1223, anddifferent end magnet assemblies 1220′ (having a pusher magnet 1225′) and1220″ (having a pusher magnet 1225″ disposed on the longitudinallyopposite end of pole assembly 1230 from pusher magnet 1224′). Poleassembly 1230 thus achieves the benefit of pusher magnets 1225′, 1225″.FIG. 17C further shows that a pole assembly 1330 can be formed of threeidentical magnet assemblies 1320 each having a lens 1328 (in addition tocentral magnet 1321 and splitter magnets 1322, 1323. Pole assembly 1330thus realizes the benefits of a ferromagnetic lens. These figures aregiven by way of example only; a pole assembly may be comprised of anytwo or more individual flux focusing magnet assemblies, and personsskilled in the art will recognize and understand how to combine theindividual flux focusing assemblies discussed herein into a poleassembly to achieve a desired set of characteristics for the intendedapplication of the pole assembly.

As illustrated in FIGS. 17D and 17E, a pole assembly may be formed froma single elongate flux focusing magnet assembly, rather than multiplemagnet assemblies. In the embodiment of FIG. 17D, pole assembly isformed of central magnet 1421, splitter magnets 1422, 1423, and pushermagnets 1424, 1425. FIG. 17E shows a similar pole assembly 1530, whichincludes splitter magnets 1522, 1523, pusher magnets 1524, 1525, andlens 1528. FIG. 17F further illustrates a pole assembly 1630 that issimilar to pole assembly 1230 except that each magnetic assembly 1620,1620′ and 1620″ includes a lens 1628, 1628′ and 1628″, respectively.

It is noted that the sections taken along lines B-B and C-C of FIG. 17Bcorrespond to the cross-sectional views of magnet assembly 720 shown inFIGS. 9A and 9B, respectively. Similarly, the sections taken along linesL-L and M-M of FIG. 17F correspond to the cross-sectional views ofmagnet assembly 1020 shown in FIG. 13 and magnet assembly 1120 shown inFIG. 14, respectively.

Multiple pole assemblies can be placed side by side to form a magneticassembly. FIG. 18 schematically illustrates a magnetic assembly 40composed of two pole assemblies, north pole assembly 30 and south poleassembly 30′. Optionally, magnetic assembly 40 may include a backingmember 35 on which pole assemblies 30, 30′ may be supported or disposed.Backing member 35 is preferably formed of a ferromagnetic material andmay be referred to as a back iron. Backing member 35 can provide areturn flux path for flux from each pole assembly, e.g. for the splittermagnets of each pole assembly to poles of adjacent pole assemblies ofopposite polarity (not shown). Further, magnetic assembly may alsoinclude a side retaining member or insert 38 between pole assemblies 30,30′ and between adjacent pole assemblies (not shown). Further, magneticassembly may include an end retaining member or insert 39 at one or bothends of pole assemblies 30, 30′.

The pole assemblies in a magnetic assembly may or may not be separatedby a spatial gap. For example, FIG. 19 illustrates a magnetic assembly1740 having a back iron 1735 and a north pole assembly 1730 (withcentral magnet 1721, splitter magnets 1722, 1723, and pusher magnets1724, 1725) and a south pole assembly 1730′ (with central magnet 1721′,splitter magnets 1722′, 1723′, and pusher magnets 1724′, 1725′)supported on back iron 1735. Each of the pole assemblies in thisembodiment is shown as being formed from a single magnet assembly,rather than multiple magnet assemblies, but this is simply for ease ofillustration and it is contemplated that each of the pole assemblies maybe formed in any of the configurations described above. In thisembodiment there is no spatial gap between the pole assemblies 1730,1730′ and they are thus in contact. Indeed, splitter magnet 1722 of thenorth pole assembly 1730 could even be affixed to splitter magnet 1723′of the south pole assembly 1730′. FIGS. 20A, 20B, and 20C show partialcross-sectional views of FIG. 19 (for simplicity of illustration, shownwithout back iron 1735), taken along lines 20A-20A, 20B-20B, and20C-20C, respectively. As shown in FIGS. 20A-20C, the top and bottomfaces of central magnet 1721 of the north pole assembly 1730 have amagnetization of north and south, respectively, while the top and bottomfaces of central magnet 1721′ of the south pole assembly 1730′ have amagnetization of south and north. In pole assemblies 1730, 1730′,splitter magnets 1722, 1723 and 1722′, 1723′, and pusher magnets 1724,1725 and 1724′, 1725′, respectively, perform the same functions asdescribed above for the various embodiments of magnet assemblies andpole assemblies that incorporate splitter magnets and pusher magnets.

FIG. 21 illustrates another embodiment of a magnetic assembly 1840.Magnetic assembly 1840 has a back iron 1835 and a north pole assembly1830 and a south pole assembly 1830′ supported on back iron 1835. Aswith the previous embodiment, each of the pole assemblies in thisembodiment is shown as being formed from a single magnet assembly,rather than multiple magnets, but this is simply for ease ofillustration and it is contemplated that each of the pole assemblies maybe formed in any of the configurations described above. Also in thisembodiment there is no spatial gap between the pole assemblies 1830,1830′ and they are thus in contact. Unlike the previous embodiment, eachof pole assemblies 1830, 1830′ includes a lens 1828, 1828′. Further,magnetic assembly 1840 includes an end insert 1839 at each end of poleassemblies 1830, 1830′, coupled to back iron 1835 (although shown asintegrally formed with back iron 1835 in FIG. 21, end inserts 1839 couldbe formed separately from, and operatively coupled with, or disposedadjacent to, back iron 1835). FIGS. 22A, 22B, and 22C show partialcross-sectional views of FIG. 21 (again, for simplicity of illustration,without back iron 1835 or end inserts 1839), taken along lines 22A-22A,22B-22B, and 22C-22C, respectively. As shown in FIGS. 22A-22C, the topand bottom faces of central magnet 1821 of the north pole assembly 1830have a magnetization of north and south, respectively, while the top andbottom faces of central magnet 1821′ of the south pole assembly 1830′have a magnetization of south and north. In pole assemblies 1830, 1830′,splitter magnets 1822, 1823 and 1822′, 1823′, and pusher magnets 1824,1825 and 1824′, 1825′, respectively, perform the same functions asdescribed above for the various embodiments of magnet assemblies andpole assemblies that incorporate splitter magnets and pusher magnets.

As noted above in reference to FIG. 18, pole assemblies may be mountedon a back iron, and may be separated by ferromagnetic side inserts orretaining members, rather than being in contact with each other. Fluxfocusing magnet assemblies such as those described herein allow the useof thinner back irons than do conventional magnet assemblies. Ingeneral, as back iron thickness is reduced, the back iron's ability tocarry flux diminishes, making flux saturation more likely. Saturationincreases the reluctance of the magnetic circuit, and the resultingreduction in flux causes a reduction in torque per Ampere when appliedin a permanent magnet machine. When flux focusing magnet assemblies suchas those disclosed herein are used, the orientation of polarity betweenneighboring poles is such that flux is encouraged to flow through theair or other separation between the poles (because a portion of fluxtravels into and out of the sides of splitter magnets), in addition tothe back iron. This relieves the back iron of some of its requirement tocarry flux, such that back iron thickness can be reduced. In contrast,in a conventional configuration of straight-polarity magnets, nearly allof the flux flowing through the magnets is carried by the back iron,including the greater amount of leakage flux that is lost to neighboringpoles, and back iron thickness must be sufficient to carry all of thisflux.

Further reductions in back iron thickness are possible whenferromagnetic retaining inserts 38 are used between poles, as will beexplained by reference to FIG. 23. Magnetic assembly 1940 shown in FIG.23A includes pole assembly 1930, back iron 1934, and side inserts 1938.Pole assembly 1930 includes one or more flux focusing magneticassemblies that include a central magnet 1921, and splitter magnets 1922and 1923, each in contact with a side insert 1938. Inserts 1938 allowmore return flux to be carried between the poles and through thesplitter magnets 1922, 1923 of pole assembly 1930. Retaining inserts1938 can either be formed directly on back iron 1934, or they can beformed separately and mounted on back iron 1934. Because retaininginserts 1938 have a lower reluctance than the air through which somemagnetic flux would otherwise pass, retaining inserts 1938 lower overallflux circuit reluctance—a benefit that is manifested as a furtherconcentration of flux in the desired location.

The size of retaining inserts 1938, particularly their height and width,can be optimized to concentrate flux in the manner desired. Optimallysized retaining inserts 1938 are high enough and wide enough to carrythe desired amount of return flux, but not so high and wide that theyprovide an alternate path for flux that would otherwise be directedacross a machine air gap, for instance. When using retaining inserts1938, the overall thickness of back iron 1934 can be reduced, becausethe retaining inserts 1938 increase the local effective thickness ofback iron 34 where necessary to avoid flux saturation.

Alternatively, individual flux focusing magnet assemblies or completepole assemblies may be mounted to a back iron with ferromagnetic magnetholders, such as described in more detail below, to achieve the sameresult. A magnet assembly or pole assembly may also include its ownferromagnetic backing member disposed at its back surface, which mayfunction to carry some or all of the flux in the return path fromadjacent magnet assemblies in adjacent pole assemblies. Such backingmembers can also function as structural supports and/or as retainingmechanisms to a larger back iron or other supporting structure thatcarries multiple such magnet assemblies or pole assemblies. Thesupporting structure can be formed in whole or in part fromferromagnetic materials and function to carry some of the flux in thereturn patch between adjacent magnet assemblies/pole assemblies, or maybe formed entirely of non-ferromagnetic materials and serve only as astructural support for the constituent pole assemblies in a magneticassembly. The individual back irons could be coupled to the larger backiron or structural support by any suitable mechanism, for example with adovetail connection.

Notably, the benefits of utilizing ferromagnetic retaining inserts 1938cannot be obtained with straight polarity magnets, because inserts 1938would effectively short the straight polarity magnets (thus drawing fluxaway from the gap) and consequently reduce the useful flux across thegap. With a flux focusing magnet arrangement, however, the angle ofpolarity of splitter magnets 1922, 1923 (which are adjacent to retaininginserts 1938) is such that the retainers carry useful flux betweenneighboring poles, rather than providing the aforementioned shortingpath between faces of adjacent magnets. Ferromagnetic retaining inserts1938 can also be implemented in a manner that provides useful structuralstiffness to magnetic assembly 1940 or larger assemblies or machines ofwhich magnetic assembly 1940 may form a part.

In the preceding embodiments, back iron, side or end inserts, and magnetassemblies or pole assemblies are shown as having rectilinearinterfaces. The interfaces need not be so limited. For example, as shownin FIG. 24A, magnetic assembly 2040 has pole assemblies 2030 (formed ofone or more magnet assemblies including a central magnet 2021, splittermagnets 2022 and 2023, and lens 2028) and 2030′ (formed of one or moremagnet assemblies including central magnet 2021′, splitter magnets 2022′and 2023′, and lens 2028′) are coupled to back iron 2035, which isformed with an upper surface having recesses shaped to conform incross-section to the cross-sectional shape of pole assemblies 2030,2030′. Essentially, this back iron configuration integrates thefunctions of the separate back iron and side inserts illustrated above,as is shown by the similarity of the flux lines to those in magneticassembly 1940 in FIG. 23. Note that lenses 2028, 2028′ have concavesurfaces. As another example, FIG. 24B shows a magnetic assembly 2140with pole assemblies 2130, 2130′ similarly “embedded” into the shapedupper surface of back iron 2135. Note that the pole assemblies areformed of magnet assemblies having a single magnet 2121, 2121′ formedwith a variable magnetic angle of polarization or nominal flux axisrelative to its top surface and having a lens 2128, 2128′ that has aflat upper surface and an arcuate, convex lower surface (correspondingto an arcuate, concave upper surface of magnet 2121, 2121′). The flatupper surface of each lens can provide the advantage of placing magnetmaterial as close as possible to a winding of a stator in a machineapplication of magnetic assembly 2140. As indicated by the orientationof the flux lines internal to magnets 2121, 2121′, not all of the fluxlines need to be oriented towards (or away) from lenses 2128, 2128′—byaligning some of the magnet domains to the surface, the magneticassembly may produce smoother waveforms.

The effect or function of end retainers or inserts is illustrated inFIG. 25, which shows magnetic assembly 2240. Magnetic assembly 2240includes north pole assembly 2230 (shown for simplicity of illustrationas being formed of a single magnet assembly having central magnet 2221,splitter magnets 2222, 2223, and pusher magnets 2224, 2225) and southpole assembly 2230′ (having central magnet 2221′, splitter magnets2222′, 2223′, and pusher magnets 2224′, 2225′). Side insert 2238 isdisposed between, and in contact with, splitter magnets 2222, 2223′, andend inserts 2239 are disposed on opposite ends of pole assembliesadjacent to, and in contact with, pusher magnets 2224, 2224′, 2225,2225′. The arrows illustrate the flux flow through inserts 2239 betweenthe pusher magnets of the pole assemblies, and the flux flow throughinserts 2238 between the splitter magnets. Not shown in FIG. 25 is thatflux leaves the upper surface of north pole assembly 2230, and entersthe upper surface of south pole assembly 2230′.

Magnetic assemblies as described above may be incorporated into variousmagnetic machines. FIG. 26A schematically illustrates components of amagnetic machine 2301, which may be, for example, a motor/generator. Thecomponents of magnetic machine 2301 can include magnetic assemblies2340, 2340′, a magnetic assembly support 2350 on which magneticassemblies 40, 40′ can be mounted, and a winding support 2360 on whichone or more conductive windings 65 can be mounted.

In this embodiment, the pole faces of magnetic assemblies 2340, 2340′are separated by an air gap (indicated as “AIR GAP” in FIG. 26A). Asindicated by the arrows across the air gap, and the arrow heads(circles) and tails (crosses) in magnetic assembly support 2350, fluxgenerally flows through the windings 2365, and changes direction bothtimes within the magnetic assembly support 2350. The nominal flux axesof the pole assemblies' constituent magnets may be oriented to convergetowards the air gap, i.e. towards windings 2365, and optionally lenses(not shown) of the constituent pole assemblies, and/or inserts or shapedback iron (not shown) of the magnetic assembly may be configured tomodify the flux field produced by the magnetic assemblies to yield adesired flux density distribution at the windings 2365.

Magnetic assembly support 2350 and winding support 2360 can be coupledto an assembly support (not shown in this figure) for relative movementwith respect to each other. For example magnetic assembly support 2350can be coupled to the assembly support for rotational motion (i.e. as a“rotor”) and winding support 2360 can be fixedly coupled to the assemblysupport (i.e. as a “stator”). If the axis of rotation of rotor 2350 isvertical in FIG. 26A (e.g. to the right of the rotor and stator), themagnetic machine 2301 is an axial flux machine. If the axis of rotationof rotor 2350 is horizontal in FIG. 26A (e.g. below the rotor andstator), the magnetic machine 2301 is a radial flux machine.Alternatively, if the magnetic support assembly 2350 moves linearly,rather than rotationally, with respect to stator 2360, the magneticmachine 2301 has a linear machine architecture.

Another configuration of a magnetic machine, which again may be amotor/generator, is shown in FIG. 26B. Magnetic machine 2401 has asingle magnetic assembly 2440 mounted on magnetic assembly support 2450.Winding support 2460 supports one or more conductive windings 2465,which are wound around a ferromagnetic core 2467, in a conventionalconfiguration.

The pole face of magnetic assembly 2440 is separated from windings2465/core 2467 by an air gap (indicated as “AIR GAP” in FIG. 26B. Asindicated by the arrows across the air gap, and the arrow tails(crosses) in magnetic assembly support 2450 and arrow heads (circles) inwinding support 2460, flux generally flows into, and changes directionin, the stator and the rotor. Any given point that carries flux in thestator sees a full flux reversal (AC flux in the core).

The nominal flux axes of the pole assembly's constituent magnets may beoriented to converge towards the air gap, i.e. towards windings 2465 andcore 2467, and optionally lenses (not shown) of the constituent poleassemblies, and/or inserts or shaped back iron (not shown) of themagnetic assembly may be configured to modify the flux field produced bythe magnetic assemblies to yield a desired flux density distribution atthe windings 2465.

As with the previous embodiment, magnetic assembly support 2450 andwinding support 2460 can be coupled to an assembly support (not shown inFIG. 26B) for relative movement with respect to each other. For examplemagnetic assembly support 2350 can be coupled to the assembly supportfor rotational motion (i.e. as a “rotor”) and winding support 2460 canbe fixedly coupled to the assembly support (i.e. as a “stator”). If theaxis of rotation of rotor 2450 is vertical in FIG. 26B (e.g. to theright of the rotor and stator), the magnetic machine 2401 is an axialflux machine. If the axis of rotation of rotor 2450 is horizontal inFIG. 26B (e.g. below the rotor and stator), the magnetic machine 2401 isa radial flux machine. Alternatively, if the magnetic support assembly2450 moves linearly, rather than rotationally, with respect to stator2460, the magnetic machine 2401 has a linear machine architecture.

An exemplary embodiment of a surface mounted magnet axial field magneticmachine, in this embodiment a motor/generator, incorporating fluxfocusing magnet assemblies as describe above is illustrated in FIGS. 27to 32. As shown in FIGS. 26 and 27, magnetic machine 2501 has arotor/stator configuration similar to that shown schematically in FIG.26A, including a segmented annular rotor 2550 that is U-shaped in crosssection and an annular segmented stator 2560 disposed between the legsof the rotor.

Rotor 2550 is coupled to a rotating rotor hub 2551 with structuralsupport members 2552. Rotor hub 2551 is rotatably mounted on an axle(not shown) extending through the central opening of stator hub 2561.Stator 2560 is attached to stator hub 2561 with structural supportmembers 2562. Stator hub 2561 is fixedly attached to a support structureand/or housing arrangement (not shown) which further maintains the fixedorientation of the stator 2560. Rotor 2550 has a first magnetic assemblysupport member 2551 and a second magnetic assembly support member 2555that is attached to the first support member 2551 using fasteners (notshown) at mounting blocks 2556 on an outer circumference of supportmembers rotors 2551 and 2555, respectively.

The stator 2560 of this embodiment may include an annular array ofstator segments 2565, each of which segments 2565 may have a circuitboard arrangement similar to that described in U.S. Pat. No. 7,109,625and in International Application PCT/US2010/000112, the disclosures ofwhich are incorporated herein by reference.

A section of the first magnetic assembly support 2551 as shown in FIG.28 is shown enlarged in FIG. 29. Pole assemblies 2530 are mounted to theback iron 2534 of first magnetic assembly support 2551. As shown in themore detailed view of several of the pole assemblies 2530 in FIG. 29,the pole assemblies are held in place on back iron 2534 with magnetholders 2536. As seen in FIG. 28, each pole assembly 2530 is composed ofa group of five flux focusing magnet assemblies 2520, aligned in theradial direction. Each of pole assemblies 2530 is a pole of themotor/generator 2501. Although not visible in FIG. 27, similar poleassemblies are also mounted to second magnetic assembly support 2555,such that a “north pole” pole assembly on second support 2555 isopposite a “south pole” pole assembly on first support 2550 and viceversa. The orientation of the poles in constituent magnets of a given“north pole” pole assembly 2530, in combination with the orientation ofthe angle of polarization of those magnets, results in magnetic fluxdirected angularly toward central magnet 2521 from splitter magnets 2522and 2523, and outward across the gap and towards the pole of oppositepolarity on the opposing magnet assembly. Similarly, the orientation ofthe poles in constituent magnets of a given “south pole” pole assembly2530, in combination with the orientation of the angle of polarizationof those magnets, results in magnetic flux from splitter magnets 2522and 2523 being directed away from central magnet 2521, and into backiron 2534, which provides a return flux path to the adjacent poles. Inmotor/generator 2501, the nominal flux direction for magnet assemblies2520 of pole assemblies 2530 is perpendicular to back iron 2534.

FIGS. 30 and 31 illustrate pole assemblies and constituent flux focusingmagnet assemblies for an alternative embodiment of a motor/generator,2601. This embodiment differs from the previous embodiment only in thateach of the pole assemblies 2630 includes at each of its radially innerand outer ends a magnet assembly that includes a pusher magnet. A magnetassembly 2620′ is disposed on the radially inner end of each poleassembly 2630, and includes a central magnet 2621′, splitter magnets2622′ and 2623′, and a pusher magnet 2625′. A magnet assembly 2620″ isdisposed on the radially outer end of each pole assembly 2630, andincludes a central magnet 2621″, splitter magnets 2622″ and 2623″, and apusher magnet 2625″. The use of pusher magnets in pole assemblies 2630further improves performance of the motor/generator 2601 byconcentrating the flux in the radial direction for improved densityacross the gap to the pole of opposite polarity on the opposing rotor.Further, in axial machines, where the pole is slightly wider at itsouter diameter than at its inner diameter, pusher magnets can be used topush the peak air gap flux density as far to the outer diameter of thepole as possible, thereby increasing the torque lever arm for the shearstresses produced at the rotor surface by the electromagnetic couplingof the rotor and the stator. This can also have the effect of reducingradial conductor length, thus improving efficiency by reducing theeffective resistance of the machine for a given current level.

In most permanent magnet machines, flux focusing magnet assemblies suchas those described above concentrate flux in the gap between the backiron on which the magnet assemblies are mounted and an opposing backiron, which may or may not have additional magnet assemblies mountedthereon. These magnet assemblies are useful for controlling leakage fluxbetween neighboring poles on the rotor, for increasing the peak fluxdensity in the gap, for adjusting the distribution of flux across thegap (to thereby achieve improved waveform quality, and for achieving abeneficial overall effective coercivity of the magnet assemblies.Ferromagnetic lenses further concentrate flux and facilitate theabove-referenced advantages. The improvement in torque per Ampere thatresults from the use of these magnet assemblies enables the use of lowergrade magnets, which are both less costly and more readily available.

Flux focusing magnet assemblies such as those described above may beused in any electromagnetic machine utilizing surface mounted magnets.For example, FIGS. 33 and 34 show a surface mounted magnet radial fieldmachine 2701 having a stator 2760 and rotor 2750. Pole assemblies 2730are shown mounted to rotor 2750. As surface mounted magnet radial fieldmachines are well known in the art, only those aspects of such machinesthat are relevant to the present invention are discussed herein.

With reference to FIG. 33, rotor 2750 of surface mounted magnet radialfield machine 2701 has a rotor back iron 2734 to which a plurality ofpole assemblies 2730 are attached. Each pole assembly 2730 includes fivemagnet assemblies, with substantially the same configuration as the poleassemblies 2630 of the preceding embodiment. Specifically, the magnetassemblies 2720′ and 2620″ on the ends of each pole assembly 2730include pusher magnets, 2725′ and 2724″, respectively.

When used in a surface mounted magnet radial field machine such asmachine 2701, the central magnet of each flux focusing magnet assemblyhas an angle of polarization in the radial direction. The angle ofpolarization of splitter magnets in radial machines has both a radialcomponent and a tangential component (i.e. tangential to the surface ofthe rotor), and the angle of polarization of pusher magnets in suchmachines has both a radial component and an axial component. Notably, ina radial field machine, pusher magnets are useful for minimizing eddycurrents at the axial edges of the rotor. Persons of ordinary skill inthe art will appreciate that in some embodiments, individual fluxfocusing magnet assemblies—or pole assemblies formed of flux focusingmagnet assemblies—may be twisted helically to reduce cogging torque.

As shown in FIG. 35, stator 2760 of motor/generator 2701 includes astator back iron 2764 and recessed windings 2762 that interact withmagnetic flux from the flux focusing magnet assemblies on rotor 2750 toturn rotor 2750 (in a motor configuration) or to generate electricity inthe windings 2762 as rotor 2750 is turned (in a generatorconfiguration).

Application of the present invention to radial field machines is notlimited to the specific embodiment shown in FIGS. 33-35; rather, any ofthe flux focusing magnet assemblies described herein could be used inplace of magnet assemblies 2720, 2720′ and/or 2720″ in those figures,and any number of flux focusing magnet assemblies (i.e. one or more)could be used to form each pole assembly of a radial machine such asradial motor/generator 2701.

Moreover, persons of ordinary skill in the art will understand thatalthough the surface mounted magnet radial field motor/generator 2701depicted in FIGS. 33-35 has an outer stator and an inner rotor, fluxfocusing magnet assemblies according to the present invention may alsobe beneficially used in surface mounted magnet radial field machineshaving an inner stator and an outer rotor. A schematic view of a surfacemounted magnet radial field motor/generator machine 2801 using fluxfocusing magnet assemblies is shown in FIG. 36. Motor/generator 2801includes a rotor 2850 with magnet assemblies 2820 mounted on back iron2834, and a stator 2860 with windings 2862 disposed in stator back iron2864.

When used in surface mounted magnet radial field machines, flux focusingmagnet assemblies such as those described above achieve the sameadvantages as described herein, including minimizing leakage flux toneighboring poles, increasing peak flux density, allowing the flux fieldto be controlled to minimize total harmonic distortion, and enabling theuse of magnet segments of varying coercivity without substantiallyaffected the overall coercivity of the flux focusing magnet assembly.Retaining inserts may be used in surface mounted magnet radial fieldmachines as well, with the same beneficial results as described above.

As another example of the potential uses of flux focusing magnetassemblies such as those described above, FIGS. 37-39 shows anembodiment of a surface mounted magnet transverse flux motor/generatormachine 2901 utilizing flux focusing magnet assemblies. Transverse fluxmachine 2901 includes stator 2960, through which a winding 2962 passes.Transverse flux machine 2901 also includes a rotor 2950, which comprisesa back iron assembly 2934 to which permanent magnets 2920 are mounted. Atransverse flux machine stator such as stator 2460 is configured toprovide one or more flux circuits through which flux passes inalternating directions as a machine rotor, such as rotor 2450, turns. Inconventional surface mounted transverse flux machines, such as thatdepicted in FIG. 3 of “Transverse Flux Machines: What For?”, IEEEMultidisciplinary Engineering Education Magazine, Vol. 2, No. 1, March2007 (from which the transverse flux machine depicted in FIGS. 37-39 isadapted), the disclosure of which is incorporated by reference herein,two parallel rows of permanent magnets are mounted on a rotor. Themagnets in each row have alternating polarities, and the rows arealigned such that north pole magnets in one row are opposite south polemagnets in the other row, and vice versa. As shown in FIGS. 38 and 39,permanent magnets 2920 of transverse flux machine 2901 are arranged influx focusing magnet assemblies such as the assemblies described above.

As shown in FIG. 39, in transverse flux machine 2901, the simplepermanent magnets of the conventional implementation of a transverseflux machine are replaced with flux focusing magnet assemblies 2920,which may be of any of the configurations described above. Flux focusingmagnet assemblies in transverse flux machines minimize flux leakage toneighboring poles as well as eddy currents on the axial sides of therotor. They also allow for increased peak flux density and can be usedto minimize total harmonic distortion. And, they enable the use ofmagnet segments of varying coercivity without substantially affectingthe overall coercivity of the flux focusing magnet assembly. Thus, allembodiments described herein can be optimized for any radial, axial ortransverse flux motors or generators that operate in a rotating manneror in a linear manner in order to concentrate flux, reduce leakage flux,control or shape flux field harmonics, obtain an overall magnet assemblycoercivity greater than the coercivity of at least one component magnetsegment, or accomplish any combination of these purposes.

Flux focusing magnet assemblies according to the present invention alsocan be used in many other applications beyond electromagnetic machines.Flux focusing magnet assemblies redistribute the magnetic field in agiven volume as compared to the magnetic field created in the samevolume by a similarly sized and shaped straight polarity magnet.Consequently, the flux density around the surface of a flux focusingmagnet assembly is different than the flux density around the surface ofa similarly sized and shaped straight polarity magnet.

One of the benefits of this feature is that a flux focusing magnetassembly can achieve a higher surface flux density—and therefore agreater magnetic force—than the theoretical maximum surface flux densityof a similarly sized and shaped straight polarity magnet. This is usefulnot only in electromagnetic machines, but also for other applicationsthat utilize a magnet's attractive or repulsive force. For example, fluxfocusing magnet assemblies are useful for magnetic lifting, where thesurface flux density of the magnet affects the maximum liftingcapability. Flux focusing magnet assemblies are also useful in magneticbearings, where opposing flux focusing magnet assemblies of the samepolarity create a greater repulsive force—and therefore a strongerbearing—than if similarly sized and shaped straight polarity magnetswere used.

Another benefit of this feature is that the flux density on the top of aflux focusing magnet assembly (i.e., the side of a flux focusing magnetassembly to which the nominal angle of polarity points) is differentthan the flux density on the bottom (i.e. the side opposite the top) ofthe flux focusing magnet assembly. Unlike straight polarity magnets,then, flux focusing magnet assemblies have a stronger magneticattraction on the top versus the bottom (or vice versa), which ishelpful when flux focusing magnet assemblies are used in applicationswhere a magnetic attraction is preferred to be stronger in one directionthan in the opposite direction. For example, flux focusing magnetassemblies are useful in tooling used to assemble and disassemblemachines that include magnetic components. This characteristic can alsobe leveraged to facilitate the installation and removal of flux focusingmagnet assemblies, because the force holding the less attractive side ofthe assembly to an object (a back iron, for example) can be overcome bythe force holding the more attractive side of the assembly to adifferent object (a piece of tooling, for example).

Yet another benefit of this feature is that the angle of polarity andrelative dimensions of the splitter and/or pusher magnets of a fluxfocusing magnet assembly can be adjusted to shape the magnetic fieldgenerated by the flux focusing magnet assembly and to tune the magneticforce distribution across the surface of the flux focusing magnetassembly. Shaping the magnetic field can be beneficial, for example, inmagnetic sensor applications, where adjusting the shape of the magneticfield can improve positional alignment resolution, reduce the materialrequired to reach a needed flux density, and improve the signalwaveform. The ability to tune the magnetic force distribution across thesurface of the flux focusing magnet assembly allows the forcedistribution to be optimized for a given application.

The applications described above are exemplary only, and persons skilledin the art will recognize that there are many other applications inwhich flux focusing magnet assemblies present one or more advantagesover traditional straight polarity magnets of a similar size and shape.

Notably, permanent magnets used in flux focusing magnet assembliesaccording to the present invention need not be rectangular or evenrhomboidal, as described above. As another example, the corners ofsplitter magnets and/or of pusher magnets could be cut back at someangle, perhaps related to the angle of polarity, to reduce overallmagnet volume without substantially compromising performance.Preferably, flux focusing magnet assemblies according to the presentinvention are shaped so as to easily be placed side-to-side orend-to-end, such as in a pole assembly used in an axial magneticmachine. For example, non-annular flux focusing magnet assemblies arepreferred.

The individual magnet segments of any one of magnet assemblies describedabove may differ from other individual magnet segments in the sameassembly in any of the ways discussed above, including energy productrating, magnetic remanence rating, operating temperature rating, andcoercivity rating; type of magnetic material from which the magnetsegment is made; and relative dimensions, including height, width, andlength.

Further, as described above, magnet assemblies may be formed ofindividual magnet segments affixed together. The same benefits andeffects, however, may be achieved using a single magnet with varyingangles of polarity, as described above.

Methods of manufacturing flux focusing magnet assemblies, such as thosedescribed above, will now be described with reference to FIGS. 39-44.

There are at least six different methods for manufacturing flux focusingmagnet assemblies. The objective of the manufacturing methods describedbelow is to orient the final magnetic polarization of each magnetsegment of these assemblies as described previously.

The first five methods described herein deal with magnets which can havemagnetic domains pre-oriented during a step of the manufacturing processto enable the invention described above. For those methods wheremagnetic domains are pre-oriented, the alignment is formed when the rawmaterial is in a condition where it can be formed by diffusion bondingor otherwise converted from either a powder, plastic, or liquid stateinto the solid magnet material which comprises a permanent magnet in thepresence of a magnetic field with a known pole orientation. With domainspre-aligned in this manner, the magnet volume is able to hold a strongermagnetic remanence upon magnetization, yielding a magnet with greaterperformance than one with randomly oriented magnetic domains. The endresult of each of these five methods is a magnet assembly wherein eachsubcomponent contains the angle of magnetization described above.

The final manufacturing method described herein creates a structurewhereby the domains of the constituent material are initially aligned ina random orientation. The final orientation of magnetization at eachpoint in the volume of the magnet is then nominally equal to thealignment of the magnetic field applied during magnetization. The netresult is that this magnet is weaker than magnets produced using thealternative methods employing domain alignment described above, but italso may be less expensive to manufacture.

In the following description of possible manufacturing methods, the term“magnet segments” refers to any of a central magnet, splitter magnet, orpusher magnet. The “applicable magnet segments” are those magnetsegments necessary to create the desired magnet assembly. For example,as explained previously, a magnet assembly may include only a centralmagnet and two splitter magnets, or it may further include one or twopusher magnets.

The proposed manufacturing methods are now described:

As seen in FIG. 40, in a first manufacturing method 3000, the applicableindividual magnet segments are first formed through, for example,diffusion bonding or adhesive bonding, in a magnetic field at 3002. Themagnetic field aligns the magnetic domains of the powdered raw materialas it is pressed into a solid. Alternatively, the applicable magnetsegments may be produced from a gas- or liquid-based raw material thatis allowed to solidify in the presence of a magnetic field to align themagnetic domains. The applicable magnet segments are then affixed toeach other, with the domains in a proper final orientation, to createthe desired magnet assembly at 3004.

If the desired magnet assembly includes a ferromagnetic lens, theferromagnetic lens is affixed to the magnet assembly at 3006.

The entire magnet assembly is then permanently magnetized at 3008 toachieve the final desired magnetic angles of polarization, taking intoaccount whether a north pole or south pole assembly is required. Forexample, in a north pole magnet assembly consisting solely of splittermagnets, such as the assembly depicted in FIG. 2B, a singlemagnetization field applied to the assembly as a whole permanentlymagnetizes splitter magnet 122 to achieve a flux direction of minus 45°relative to the nominal flux direction of the magnet assembly, andpermanently magnetizes splitter magnet 121 to achieve a flux directionof plus 45° relative to the nominal flux direction.

As shown in FIG. 41, in a second manufacturing method 3100, theapplicable magnet segments are first formed at 3102 by one of thetechniques described above for method 3100. Each of the applicablemagnet segments is then permanently magnetized at 3104 to have thedesired angle of polarization, taking into account whether the magnetsegments will be assembled into a north pole or a south pole assembly.For example, a north pole central permanent magnet is permanentlymagnetized with an angle of polarization parallel to and in thedirection of the nominal flux direction, while a south pole splittermagnet is permanently magnetized with an angle of polarization rangingfrom 0° to less than 90° greater than or less than the opposite of thenominal flux direction.

Finally, the magnet segments are affixed together at 3106 as requiredfor the desired magnet assembly, and a ferromagnetic lens, ifapplicable, is affixed thereto at 3108. If a pole assembly consisting ofmultiple magnet assemblies is desired, the multiple magnet assembliescan be affixed together to form a single pole assembly, and aferromagnetic lens, if applicable, can be affixed thereto.

As shown in FIG. 42, in a third manufacturing method 3200, a singlemagnet is formed at 3202 (by one of the techniques described above) in acomplex magnetic field that is equivalent to the domain alignment of thedesired magnet assembly to align the magnetic domains in a continuouslyvariable manner. The single magnet is then permanently magnetized at3204 in a magnetic field such that each portion of the magnet issaturated in the proper angle of polarization. For example, if a northpole-oriented magnet assembly is desired, the single magnet ispermanently magnetized such that the center portion of the magnet has anangle of polarization parallel to and in the direction of the nominalflux direction, and the side portions of the magnet have an angle ofpolarization offset from the nominal flux direction by any angle lessthan 90° greater than or less than the nominal flux direction. To form acorresponding south pole magnet assembly, the magnetization is appliedin the opposite direction.

If the desired magnet assembly includes a ferromagnetic lens, then theferromagnetic lens may be affixed to the single magnet at 3206 after ithas been permanently magnetized. Alternatively, ferromagnetic lens maybe already located prior to magnetization.

As shown in FIG. 43, in a fourth manufacturing method 3300, theapplicable magnet segments are formed at 3302 (by one of the techniquesdescribed above) in a magnetic field to align domains. The applicablemagnet segments are then affixed at 3304 to a magnet assembly supportmember, such as one of the back iron or other members described above inconnection with various embodiments, using a fixture to hold the magnetsegments in intimate contact with each other while they are affixed tothe support member. If a pole assembly consisting of multiple magnetassemblies is desired, then each of the magnet assemblies is affixed tothe support member in the same manner. If the desired magnet assembly orpole assembly utilizes a ferromagnetic lens, then the lens is affixed tothe magnet assembly or the pole assembly at 3306. The entire magnetassembly (or pole assembly) is then magnetized at 3308 with the propermagnetic polarization as described above. This method favorably providesease of manufacturing by enabling the use of simplified tooling for theplacement or removal of magnet assemblies on an annular such as the onedescribed above.

As shown in FIG. 44, in a fifth manufacturing method 3400, theapplicable magnet segments are formed at 3402 (by one of the techniquesdescribed above) in a magnetic field to align domains. The applicablemagnet segments are then affixed at 3404 to a magnet assembly supportmember, such as one of the back iron or other members described above inconnection with various embodiments, using ferromagnetic retaininginserts to hold the magnet segments in contact while they are affixed tothe support member. If a pole assembly consisting of multiple magnetassemblies is desired, then each of the magnet assemblies is affixed tothe support member in the same manner. If the desired magnet assembly orpole assembly utilizes a ferromagnetic lens, then the ferromagnetic lensis affixed to the magnet assembly or the pole assembly at 3406. Theentire magnet assembly (or pole assembly) is then magnetized at 3408with the proper magnetic polarization as described previously.

As shown in FIG. 45, in a sixth manufacturing method 3500, a powdercontaining hard magnetic compounds is bound together at 3502 using aseparate binder material, such as epoxy, resulting in an isotropic solidwith constituent hard magnetic particles having random magnetic domainalignment. In some embodiments, the powder used for this step isanisotropic, with domain alignment related to the crystal structure, andeach particle of the powder ideally being nearly either a single crystalgrain, or single magnetic domain.

If the desired magnetic assembly includes a ferromagnetic lens, the lensis affixed to the newly-formed solid at 3504.

The solid is permanently magnetized at 3506 by subjecting it to acomplex magnetic field having the magnetic polarization of the desiredmagnet assembly. For example, if a magnet assembly having a range ofpolarization angles from center to edge is desired, the complex magneticfield has a variable angle of polarization from center to edge. Becausethe solid is originally isotropic with random domain alignment, thesolid will magnetize in whatever orientation the magnetization field isapplied.

In addition to the methods described above, each of the magnet segmentsdescribed herein, in addition to the ferromagnetic lens, could also bemade from powder, cooled from a liquid, or cooled from a near liquid,and then pressed into the proper shape. For example, a ferromagneticlens could be formed directly in its position in a magnet assembly.Additionally, for magnet assemblies including a ferromagnetic lens, eachof the magnet segments could be made from powder, cooled from a liquid,or cooled from a near liquid, then molded around the lens to form thedesired magnet assembly. Alternatively for magnet assemblies including aferromagnetic lens, a notch may be machined into the top of the affixedmagnet segments and used in affixing the ferromagnetic lens to theaffixed magnet segments to form the desired magnet assembly.

1.-43. (canceled)
 44. A method comprising: disposing a first magnetadjacent to a second magnet, the first magnet having its magneticdomains aligned parallel to a first axis, the second magnet having itsmagnetic domains aligned parallel to a second axis, the disposingincludes disposing the first magnet and the second magnet so that thefirst axis is non-parallel with the second axis; after the disposing,permanently magnetizing the first magnet and second magnet.
 45. Themethod of claim 44, further comprising: before the disposing, forming inthe presence of a magnetic field each of the first magnet and the secondmagnet by one of diffusion bonding and allowing a gas-based orliquid-based raw material to solidify to align the magnetic domains ofeach of the first magnet and the second magnet.
 46. The method of claim44, further comprising disposing a ferromagnetic lens adjacent to atleast one of the first magnet and second magnet.
 47. The method of claim44, wherein the disposing includes disposing the first magnet on a firstside of the second magnet, and further comprising, before thepermanently magnetizing: disposing a third magnet on the side of thefirst magnet opposite to the second magnet, the third magnet having itsmagnetic domains aligned parallel to a third axis, the disposing thethird magnet including disposing the third magnet so that the third axisis non-parallel with the second axis and oriented towards the first axisand the second axis in a direction above the magnets.
 48. The method ofclaim 44, wherein the disposing includes disposing the first magnet on afirst side of the second magnet, and further comprising, before thepermanently magnetizing: disposing a third magnet on an end of the firstmagnet, the third magnet having its magnetic domains aligned parallel toa third axis, the disposing the third magnet including disposing thethird magnet so that the third axis is non-parallel with the second axisand oriented towards the first axis and the second axis in a directionabove the magnets, the first axis, the second axis, and the third axisbeing non-coplanar.
 49. The method of claim 44, wherein the disposingincludes disposing the first magnet and the second magnet on aferromagnetic support member.
 50. The method of claim 44, wherein thedisposing includes disposing a ferromagnetic retaining insert betweenthe first magnet and the second magnet. 51-56. (canceled)
 57. The methodof claim 44, wherein the angle between the first axis and the secondaxis is approximately 45°.
 58. The method of claim 44, wherein the firstmagnet has a rating for at least one of energy product, magneticremanence, operating temperature, and coercivity that is different thana rating for the second magnet.
 59. The method of claim 44, wherein thefirst magnet is formed from a magnetic material that is different than amagnetic material from which the second magnet is formed.
 60. The methodof claim 44, wherein the first magnet has at least one of a lateral anda longitudinal cross section that has a different dimension than adimension of at least one of a lateral and a longitudinal cross sectionof the second magnet.